The hazard analysis should result in a written report documenting the hazards found, and provide recommendations for controlling those hazards, along with a schedule for when controls will be implemented. The report should include documentation of any actions that were taken, and how the changes will be communicated to various stakeholders such as the operations, maintenance, and safety departments. OSHA has a list of hazard analysis methods they deem acceptable. The basic information this team is provided with includes:.
Applying the principles of gemba the team goes to the field and walks down the process, and talks with the people who are involved in operating and maintaining the process equipment. What if fluid viscosity should exceed the specification? What if the bearing cooling water pump fails? They look at the entire process from the receipt of raw materials through the delivery of the finished product to the customer.
The result is a list of possible hazard conditions along with recommended actions that can be taken to protect against undesirable outcomes. A checklist hazard analysis begins with an existing safety checklist. It may have been created by an individual, or be the result of a previous hazardous analysis. A typical checklist includes items such as:. The team goes through the checklist item by item, to stimulate questions about the process and possible hazards. The final result is a set of questions about possible hazards.
The team discusses these, reaching agreement on what is truly hazardous. They develop a list of recommendations for eliminating or protecting against those hazards and may recommend extended research of some of the questions. A Hazard and Operability Study HAZOP systematically identifies all of the ways in which operating conditions can deviate from the intended design, with the result being a safety hazard or an operating problem. A team of experienced people, who are familiar with the process brainstorm potentially hazardous situations.
Drum is mislabeled? Wrong powder in the drum? Drum hoist is not used? Two drums are added? Drum is misweighed? Drum hoist fails? Drum is corroded? Ventilation at mixing tank is not operating? Granular powder becomes dusty? Tank liquid level too high? Example of Completed Step No. Ventilation at Mix Tank is not operating? Back injury potential when breaking up clumps. Quality issue only. If wet, could cause exotherm. Back injury potential. Leg, foot, back, arm injury.
Same as above. Possible burn. Possible caustic splash as well as quality issue. Example of Completed Step Nos. If done correctly, reviewing the potential equipment failures and human errors can point out the potentials for not only safety and health improvements but also the opportunity to minimize operating and quality problems. Including the operators and trades personnel in the review can bring a practical reality to the conclusions that will be reached.
In other words what is the risk. For example, consider the following risk judgments and recommendations to the answers in our example as illustrated in Figure C Design delumping equipment. Contact vendor. Include inspection in procedure. Require 2 nd check on weight.
Ensure hoist on PM program. Include vent check in SOP. None beyond existing procedure. Use goggles and apron. The hard work of conducting the analysis has been competed. The important work of reporting the results still remains. The make up of the organization generally determines to whom and how the results get reported.
Usually, the department or plant manager is the customer of the review. The leader of the review team will generate a cover memo that details the scope of the review as well as the major findings and recommendations.
In some organizations, the report recommendations will also include who has been assigned the responsibility to follow up and time frame. In other cases, a separate staff or function will review the recommendations and determine the actions required. A periodic report is then generated to summarize the present status of each of the recommendations. Those organizations that have a well developed hazard review program require follow-up assignments every three to five years based on the associated hazard levels.
These questions can be modified according to experiment or process. Human errors occur regardless of training and experience. Human error factors may drive consideration of written SOPs, a decision for engineering controls, etc. The following questions concern utilities, which are key to the support of any experiment or process:.
Consideration of failure of materials or components may result in decisions for additional controls or changes to higher rated or alternative types of materials and components. This should be included since, despite best efforts with hazard reviews and training, incidents will occur.
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Join the Division Renew Your Membership. Email the Safety team at safety acs. What is Safety Culture? Control Banding. What it is A technique using brainstorming to determine what can go wrong in specific scenarios and identify the resulting consequences.
Who's involved Appropriate for both individuals and teams. When to use Simple research applications Complex processes Research environment, where teaching is the core mission Assessing existing processes and experiments. Training required Minimal. Requires someone to be familiar with the equipment, processes, etc. Overview What will happen if toxic gases leak into a liquid pipeline? What-if Analysis can be applied at virtually any point in the laboratory evaluation process.
How to Conduct a What-if Analysis. Team Kickoff The team leader walks the team through each step of the What-if Analysis. Generate What-if Questions The team generates What-if questions relating to each step of the experimental procedure and each component to determine likely sources of errors and failures. Evaluate and Assess Risk The team considers the list of What-if questions, one-by-one, to determine likely sources of errors.
How to Assess Risk 4. Assign Follow-up Action Responsibilities are assigned for follow-up action s.
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